Introduction First of all I thank the organizers of this seminar to have given me this opportunity to present a paper before

this august gathering on Up-gradation of power equipment in Rolling Mills for Energy Efficiency. I am also glad to be in Mandi Govindgarh Steel City of North India. I am Amitabh K Sinha, DGM, Rolling Mills. with MECON Ltd a GOI company engaged in design engineering & turn key project mainly related with metal industry, though MECON has the distinction of executing diverse projects such as design, supply, erection & commissioning of Second Launch Pad at ISRO, pad from where the prestigious Chndrayan was launched last year this speaker is lucky enough to get deeply involved in this project. & other major turnkey projects of MECON such as CRM-2 of Bokaro, LMMM of Vizag Steel plant, Stainless Steel plant at Salem etc. during 38 years with MECON excluding 1 year as VP-Projects with Jindal, Hissar.

Contents What is energy efficient system? ................................................................................. 3 Why energy efficient Rolling Mills? ............................................................................ 4 How to have energy efficient rolling mills? ................................................................. 9 Selection of efficient technology: ............................................................................. 9 Selection of efficient equipment............................................................................. 10 Role of Employer & Engineers .............................................................................. 10 Environmental Issues involved .................................................................................. 10

What is energy efficient system?

World energy council defines energy efficiency or improvement of energy efficiency as following: Energy efficiency improvements refer to a reduction in the energy used for a given service (heating, lighting, etc.) or level of activity. The reduction in the energy consumption is usually associated with technological changes, but not always since it can also result from better organisation and management or improved economic conditions in the sector ("non-technical factors"). In some cases, because of financial constraints imposed by high energy prices, consumers may decrease their energy consumption through a reduction in their energy services (e.g. reduction of comfort temperature; in car mileage). Such reductions do not necessarily result in increased overall energy efficiency of the economy, and are easily reversible. They should not be associated with energy efficiency. To economists, energy efficiency has a broader meaning: it encompasses all changes that result in decreasing the amount of energy used to produce one unit of economic activity (e.g. the energy used per unit of GDP or value added). Energy efficiency is associated with economic efficiency and includes technological, behavioural and economic changes. Energy efficiency is first of all a matter of individual behaviour and reflects the rationale of energy consumers. Avoiding unnecessary consumption of energy or choosing the most appropriate equipment.

Why energy efficient Rolling Mills?

There is a global agenda for energy efficiency as this is connected with depleting reserves of fossil fuels, pollution and global warming. This necessitates design of metal industries for energy efficient operation. While Energy efficient systems are needed for all the activities we are involved with, we may focus this aspect with respect to Rolling mills seen in the perspective of metal industry as whole. Steel production is highly energy intensive industry. Although in steel produced from scrap some energy used for conversion from ore is saved, electrical energy consumed is considerable due to use of electrical arc furnaces. In Indian perspective approx. 1/3rd cost of steep production is on account of energy costs. As we know that major consumers of electrical energy in metal industry are electrical furnaces, cells in Al plants and rolling mills. Being one of the major consumers of electrical energy in a steel plant environment, rolling mill is a natural target for energy efficient system and operations. The implication may be visualized by the fact a 2000 mm continuous HSM needs 12 nos. stands of 10 MW for main stand itself or a 1250 mm Tandem Cold mills needs 5 nos. 5 MW main stands, a 0.7 MT merchant mill may have a power demand of about 35 MW. Further due to speed controls needed rolling mills often produces lot of reactive power & harmonics adversely affecting the efficiency of the system.

A material flow diagram showing units being planned for 7 MT expansion of Bokaro Steel CRM shows that latest trend is to adopt energy efficient processes.

SRRM Sector In Indian Steel Re-Rolling Mill (SRRM) Sector comprises of about 1200 rolling mills. These mills are concentrated in 6 areas namely i.e. Mandi Gobindgarh, DelhiGhaziabad-Faridabad, Chennai, Kolkata and Nagpur Wardha, Gujrat. Though technologically the SRRM Sector cannot be termed progressive it forms an important link in the over all supply chain of steel in the country. Approx 57 % of total secondary steel in the country is produced in this sector. SRRM sector is also major customer of primary steel producers consuming almost 50 % of relevant sizes of primary steel. These mills have grown haphazardly and use outdated technology. These factors lead to inefficient use of energy apart from wastages. These mills though have low investment cost they have high cost of production. The flow chart of the process shows 2 energy in-efficient processes needing attention furnace & rolling mills.

Energy being one of the major input to rolling mills, saving or efficient use of energy definitely is a major factor if re-rolling mills have to maintain competitiveness. Energy Efficiency From the facts emphasized above, future growth prospects of steel industry largely depend on efficient use of available energy hence small and medium enterprises not only need greater awareness but also technical, financial and institutional support in order to develop and adopt energy efficient technologies.

Further to above reasons, to economists Energy saved is energy produced as well as profit earned.

How to have energy efficient rolling mills?

Energy efficiency in rolling mills are achieved through following processes:

1. Selection of efficient technology. 2. Selection of efficient equipment. 3. Role of Employer, Engineers

Selection of efficient technology:

While emphasis in technologies adopted earlier was productivity, new emphasis is still productivity but using efficient processes. In the rolling mills arena technological processes as given below are being adopted: Hot charging. CSP plants Combination of mills & process lines such as PL-TCM. Lighter mill design cantilever / housing less stands / mill blocks. High reduction mills 6 Hi, 20 Hi etc leading to less numbers of passes. Economy of scale or mills having large production Since energy loss of most processes have fixed & variable components & hence bigger units tend to be more energy efficient. Improved furnace design improved recuperator, top & bottom fired, walking beam furnace. Energy recovery waste heat boilers, top recovery turbines. Latest modernization trends in steel industry also indicates use of above technology in modern mills / plants. Energy efficiency stems from cutting down on waste through the means of Reduction, Recovery and Recycling. Energy Efficient Technologies are win-win technologies as they reduce pollution on one hand and enhance profits on the other hand. A large scale capacity building initiative was planned for Rolling Mill Personnel to tap the energy saving potential in the sector.

Selection of efficient equipment

Once efficient technology is selected, next task is to select suitable efficient equipment. There are many energy efficient products such as: Use of energy efficient motors. Use of energy efficient lighting Use of energy efficient HVAC equipment Use of efficient transformers, conversion equipment Use of synchronous motors for better efficiency & PF improvement in low speed high power application. Harmonics & PF compensation equipment.

A brief discussion on selection of electrical equipment is called for here. The major items to improve efficiency are listed below. Increased Use of MV equipment to reduce line losses. Use of latest AC drives based in IGBT / IGCT etc. These drives by using latest power devices have lesser switching losses compared to SCR based DC drives. Further by reducing harmonics & PF in some configuration, greater efficiency is achieved. Latest AC drives tend to have 99.5% efficiency and unity power factor. Use of VFD for fans / pumps so as to run at reduced speed to reduce flow instead of using dampers etc. (Q N3 ) Optimized selection of motors in stead of using several safety factors at each stage.

Role of Employer & Engineers

Environmental Issues involved

According to a study 3 main contributor to green house gases in India are: Power sector 51 %, Transport 16% Steel 10 %. Further CO2 emissions per ton of steel in India is roughly double of those in advanced countries : Corus Holland 1200 kg/ T, Dofasco, Canada _ 1300 kg/T, Raahe Steel, Finland 1900 kg/ T, Tata Steel : 2600 kg/T, SAIL : 2900 kg/T.

However the consolation is that these figures as well as energy consumed per T of steel is consistently decreasing. There has been 30% decrease in energy consumed per T steel in SAIL plants during 1990 to 2005. Potential Opportunity Area Potential Opportunity Area Use of renewable energy at remote mines Use of renewable energy at remote mines Switching over from THF to BOF Switching over from THF to BOF Increased use of Continuous Casting facilities Increased use of Continuous Casting facilities Installation of Direct Reduction Processes Installation of Direct Reduction Processes Installation of Top Recovery Turbine (TRT) Installation of Top Recovery Turbine (TRT) Sensible heat recovery from Sinter Cooler Sensible heat recovery from Sinter Cooler Replacing energy Replacing energy-intensive motors intensive motors by efficient motors by efficient motors Waste Heat recovery projects including power generation Waste Heat recovery projects including power generation Efficient re Efficient re-heating furnace and soaking pits in Rolling Mills heating furnace and soaking pits in Rolling Mills Switch over from coal Switch over from coal-fired to gas fired boilers fired to gas fired boilers Reduction in flaring of BF & CO gas Reduction in flaring of BF & CO gas BOF gas recovery BOF gas recovery Use surplus gases for steam / power generation Use surplus gases for steam / power generation Green Belt Development & afforestation to act as a sink for

A tree with 150 m2 projected area in 100 years produce as much Oxygen as is consumed as is consumed in 20 years by a man. i.e. one human being requires 5 large canopy trees for his oxygen consumption.